Modular wall corner connector



Sept 1970 w. B. WlLKlNS 3,529,394

MODULAR WALL comma CONNECTOR Filed Sept. 50, 1968 w 2 Sheets-Sheet 1 INVENTORI Vl/ILUAM BURBETTE- .21 W1 LKINS wwmgflwww ATTORNEYS 22, 1970 w. a. WILKINS MODULAR WALL CORNER CONNECTOR 2 Sheets-Sheet 2 Filed Sept. 30, 1968 28 INVENTOR: LuAM BUEBETTEWI LN NS fiwatmwgmwmb-m ATTORNEYS United States Patent 3,529,394 MODULAR WALL CORNER CONNECTOR William Burdette Wilkins, Louisburg, N.C., assignor to Comstruct, Inc., Lincolnton, N.C., a corporation of North Carolina Filed Sept. 30, 1968, Ser. No. 763,534 Int. Cl. E04b 2/18; E04c 1/10, 3/36 U.S. Cl. 52--731 9 Claims ABSTRACT OF THE DISCLOSURE An elongate four-sided, shell-like corner joint member, preferably formed of laminated paper, and having a tongue projecting from one side thereof, and a groove formed in an adjacent side thereof with the tongue and groove extending in substantially right-angular relationship to accommodate and support the proximal respectively grooved and tongued edges of a pair of relatively right-angularly disposed building wall panels. Also, a method of making such a corner joint member in which a tongue component and a groove component are formed separately and then adhesively interconnected with the tongue element and groove element extending in substantially right-angular relationship.

This invention relates to building wall structures and, more particularly, to an improved corner joint member for interconnecting the proximal ends of a pair of rightangularly disposed building wall panels.

It is an object of this invention to provide an improved corner joint member for interconnecting in substantially right-angular relationship a pair of building wall panels, wherein the corner joint member is provided with a longitudinal tongue at one side thereof and is formed with a longitudinal tongue-receiving groove therein at an adjacent side thereof extending at a substantially right angle to the longitudinal groove, and wherein the corner joint member is of lightweight construction, may be readily molded from laminated paper, and may be easily erected to interconnect the panels.

It is a more specific object of this invention to provide a corner joint member of the character described which is four-sided and wherein the four sides of the joint member include respective walls defining a continuous external profile cross-sectional configuration to the joint member, all of the Walls being formed of a relatively thin rigid material, wherein the tongue-receiving groove formed in one side of the joint member is adapted to receive a tongue of the same configuration as the tongue disposed in right angular relation thereto, and also wherein the tongue-receiving groove is of such depth and so positioned that it extends completely behind the corresponding tongue with the bottom of the groove being positioned closely adjacent the opposing side of the corner joint member.

Another object of the invention is to provide a method of making a corner joint member of the character described, which includes forming a flanged tongue component and a separate flanged groove component, modifying the two components thus formed by severing one of the flanges from each of the components, then adhesively interconnecting those edges of the two components from which the respective flanges were previously removed, and adhesively interconnecting other flanges of the two components, and wherein the two components are relatively positioned during the step of adhesively interconnecting the same with the groove of the groove component being disposed adjacent and in substantially rightangular relation to that side of the thus formed corner joint member which has the tongue thereon.

"ice.

Some of the objects of the invention having been stated, other objects will appear as the description proceeds when taken in connection with the accompanying drawings, in which- FIG. 1 is a fragmentary view of a pair of adjacent upright and relatively right-angularly disposed wall panels, showing the same interconnected by means of the corner joint member of the instant invention, with the central portions of the panels and corner joint member being broken away;

FIG. 2 is an enlarged sectional plan view through the improved corner joint member and portions of adjacent relatively right-angularly disposed wall panels shown in FIG. 1;

FIG. 3 is a plan view of the corner joint member disassociated from the wall panels of FIGS. 1 and 2; and

FIGS. 4 and 5 are plan views of two components as modified to join them together in making a corner joint member such as that of FIG. 3, and which corner joint components may, before modification, be of the same identical configuration as the adjacent tongue joint and groove joint members of the panels shown in FIGS. 1 and 2.

Referring more specifically to the drawings, the numeral 10 broadly designates the improved corner joint member of the instant invention positioned at the juncture of and interconnecting the proximal vertical side edge portions of a pair of adjacent upright and relatively right-angularly disposed wall panels broadly designated at 11, 12. Panels 11, 12 are suitably secured to and sup ported by a floor 13. The wall panels 11, 12 are characterized by having a longitudinally extending groove in, and a longitudinally extending projecting tongue on, the proximal side edges thereof. More specifically, wall panels 11, 12 may be of the type disclosed in my copending application entitled Modular Building Wall Structure with Electrical Raceway Means, Ser. No. 763,508, filed of even date herewith, and to which reference is made for a more detailed disclosure thereof.

Essentially, each panel 11, 12 comprises a substantially rectangular core 20 which may be in the form of a honeycomb made from kraft paper, cardboard or other paper products, and the interstices of which may contain a suitable insulation material 21, such as polyurethane foam molded integral therewith. As shown in FIGS. 1 and 2, insulation material 21 is substantially flush with the outside surface of core 20, and may penetrate about halfway through core 20. If desired, insulation material 21 may extend from the outside face to the inside face of core 20. Further, core 20 also may be in the form of a sheet or laminated sheets of fiberboard or similar material.

Positioned about the core 20 of each panel 11, 12 is a peripheral framework, only the upper and lower framework members and one side framework member being shown in association with each of the panels in FIGS. 1 and 2. The framework of each panel 11, 12 may comprise an upper elongate structural member 23 and a lower structural member 24, the lower structural member 24 being shown in the form of an elongate hollow raceway adapted for the installation therein of electric wires or conductors, not shown. The hollow raceway members 24 may be secured to floor 13 by any suitable means, not shown, but being clearly disclosed in said copending application.

The proximal upright side edges of the relatively rightangularly disposed panels 11, 12 are defined by respective vertically disposed elongate first and second side edge joint members 25, 26 of shell-like construction and which are of generally M-shaped and U-shaped cross-sectional configuration, respectively, so that they may be readily molded or extruded and so that their proximal edges define a groove 25a and a tongue 26a, respectively. Thus, the first and second side edge joint members 25, 26 are respectively in the form of a groove member and a tongue member.

The internal sidewalls of groove 25a of first side joint member 25 are tapered or converge inwardly toward the respective core 20 so as to tightly receive therein a similarly tapered tongue 1%, to be later described, on the corner joint member 10. The tongue 26a of second side edge joint member 26 also has external sidewalls which are tapered or diverge inwardly toward core 20 of panel 12 so as to complement and be tightly received in the similarly tapered groove a on the corner joint member 10.

The outer edge portions of the sidewalls of groove 25a in side edge joint member 25 curve outwardly in opposing relation to each other and then curve back generally upon themselves to form a pair of opposing side flanges 25b, 25c on the first side edge joint member 25 associated with panel 11. Similarly, the inner end portions of opposed side walls of tongue 26a of second side edge joint member 26 flare outwardly in opposing relationship to each other to form wing portions 26d thereon which have opposing side flanges 26b, 26c formed on the ends thereof. The pairs of side flanges 25b, 25c and 26b, 26c straddle adjacent side edge portions of, and fit in suitable recesses formed in, opposing faces of the cores of the respective wall panels 11, 12.

As shown in FIG. 1, each of the upper structural members 23 may be of substantially the same cross-sectional configuration as that of the first side edge joint member 25. It is preferred that upper structural member 23 and side edge joint members 25, 26 are of shell-like construction and molded from paper laminations impregnated with and/or bonded together with a phenolic resin or other suitable adhesive.

Facing members or sheets 27, 28 overlie opposing sides of each core 20. Peripheral portions of facing members 27, 28 at least partially overlie the framework members 23, 24 of the respective panels 11, 12. The adjacent substantially straight vertical edges of facing members 27 on panel 11 preferably are substantially flush with the outer edge of first side edge joint member 25 (FIG. 2). Also, the adjacent edges of those facing members 27, 28 of panel 12 preferably are substantially flush with those wing portions 26d of second side edge joint member 26 where the flared sidewalls of tongue 26a are connected to flanges 26b, 260. The proximal side edges of the adjacent inner facing members 27 may be trimmed, if necessary, so that such side edges may fit in abutting or other desired relation to each other.

Any suitable adhesive material may be employed for bonding facing members 27, 28 of each panel to opposing sides of the corresponding frameworks and, of course, facing members 27, 28 also may be bonded to opposing sides of the respective cores 20. Thus, it can be appreciated that all the elements 20, 21, 23, 24 of each panel 11, 12, as well as the respective side edge joint members 25, 26, are integral parts of the respective panels 11, 12.

Facing members 27, 28 may be made from sheet material which is appropriate to the building; such material may diifer as between that on the outside of the building and that on the inside surface of a wall. Facing members 27, 28 may be made of any suitable self-sustaining material such as rigid or semi-rigid plastic material, wood veneer, sheet metal, etc. The facing members 28 form outside wall surfaces and are, therefore, preferably made of water-impervious material such as fiber glass sheets. The material may be finished to simulate wood graining, tile, marble, linen or any other attractive finish. Corner joint member 10 will now be described in detail.

Corner joint member 10 is of four-sided shell-like construction and comprises first and second adjacent sides 31, 32 positioned in substantially right-angular relationship. The longitudinal tongue 10b of corner joint member 10 is of lesser thickness than the first side 31 and defines a third side of the joint member located in opposing relation to the first side 31. Tongue 10b extends substantially throughout the length of corner joint member 10. The fourth side of corner joint member 10 is located in opposing relation to the second side 32 and has the longitudinally extending tongue-receiving groove 10a formed therein, which is of a depth greater than one-half the width of the first side 31 and extends substantially completely behind tongue 10b with the bottom of groove 10a being positioned closely adjacent the second side 32 of corner joint member 10. It will be noted that the four sides of corner joint member 10 include respective walls defining a continuous external pro-file crosssectional configuration to the joint member 10, with all of the walls being formed of a relatively thin rigid material; preferablylaminated paper.

In order that the corner joint member 10 retains its external configuration as heretofore described, a reinforcing strip 33, of about the same thickness as and preferably formed of the same material as the walls of the joint member 10, extends parallel with and is adhesively secured to the inner surface of that wall defining the second side 32 of the corner joint member 10. Any suitable adhesive, such as a phenolic resin, may be employed for adhesively securing the reinforcing strip 33 to the inner surface of that wall defining the second side 32 of corner joint member 10. The wall of corner joint member 10 which defines the bottom of the groove 10a also preferably abuts and is adhesively secured to the inner surface of reinforcing strip 33.

Opposing sidewalls of tongue 10b diverge relative to each other toward the second side 32 of corner joint member 10, and toward the third side thereof defined by groove 10a, and the exterior surfaces of those walls defining opposite sides of the groove 10a are rounded at their juncture with the first side 31 and the tongue 10b. If so desired, and to lend further rigidity to the corner joint member 10, an additional reinforcing strip 34 may be adhesively secured to the inner surface of that sidewall of groove 10a adjacent tongue 10b, with the second reinforcing strip 34 being positioned in engagement with the inner surface of the corresponding rounded portion of the corner joint member at the juncture of those adjacent Walls defining groove 16a and tongue 1%.

In the process of erecting Wall panels 11, 12 and interconnecting the same through the medium of the corner joint member 10, the mating surfaces of the corresponding tongues and grooves on the panels 11, 12 and corner joint member 10 may be coated with a suitable adhesive, whereupon either one of the panels 11, 12 may be erected in upright position, the corresponding side of the corner joint member placed in mating relation thereto, and then the other of the two panels may be erected in upright position and moved along the floor 13 to position the proximal edge of the latter panel in mating relation to the other corresponding side of corner joint member 10. For example, assuming that panel 11 is first installed in an upright position as shown in FIG. 1, the tongue 10b on corner joint member, with a suitable adhesive applied thereto, may be positioned in mating relation with the groove 25a in the first side edge joint member 25 of panel 11. Thereupon, panel 12 may be placed in upright position in right-angular relation to panel 11, and with a suitable adhesive applied to the tongue 26a of second side edge joint member 26, the latter tongue 26a may be moved into mating relation with the groove 10a in the corresponding side of corner joint member 10, thus providing fixed mating connections between the panels 11, 12 and corner joint member 10.

In order to make a corner joint member 10 according to the method of the present invention, there will be observed in FIGS. 4 and 5 a pair of first and second elongate thin-walled corner joint components 25', 26'. Components 25, 26 also may be termed as groove and tongue elements, respectively. Components 25', 26' are of substantially M-shaped and substantially U-shaped crosssectional configuration, respectively.

By comparing FIGS. 4 and 5 with FIGS. 1 and 2, it will be observed that components 25", 26' are of the same configuration as the respective first and second side edge joint members 25, 26 of panels 11, 12. Accordingly, components 25', 26 will bear the same reference characters as the respective side joint members 25, 26 of FIGS. 1 and 2, with the prime notation added to avoid repetitive description.

Although there are no cores or other panel components associated with the corner joint components, it will be noted that the elongate first component 25' (FIG. 4) is characterized by a pair of opposing side flanges 25b, 25c straddling the U-shaped portion therebetween, the latter of which defines a tongue-receiving groove 25a with the ends of the legs of the U-shaped portion being rounded and integrally connected to corresponding side edge portions of flanges 25b, 250'.

It will also be noted that the second component of FIG. 5 is of generally U-shaped cross-sectional configuration and has a tongue 26a in the form of a relatively small U-shaped portion adapted to fit in the groove 25a of the first panel 11 in FIGS. 1 and 2. The legs of the substantially small U-shaped portion defining tongue 26a also flare outwardly in the form of diverging wing portions 26d. The opposing side flanges 26b and 26c are formed integral with and extend outwardly from the distal ends of the wing portions 26d and away from the tongue 26a. The components 25, 26' are preferably made from laminated paper.

In order to modify the first and second components 25, 26 of FIGS. 4 and 5 so that they may be assembled and collectively form a corner joint member of the form indicated at in FIGS. 1-3, one of the wing portions 26d and its corresponding flange (flange 26b in this instance) are severed from the second component 26 as indicated in dotted lines in FIG. 5. Such severance preferably is effected diagonally across and about midway of the corresponding wing portion 26d and defines a free edge 35 thereat.

In a manner similar to that of flange 26b, it will be noted that flange 25b of first component 25 is severed from the first component, as represented by the dotted line in the upper portion of FIG. 4, and such severance is preferably effected diagonally across flange 25b adjacent the rounded outer end of a corresponding sidewall of the groove 25a to form a free edge 36 adjacent that side of component 25 having groove 25a therein. If necessary, the other flange 250' of first component 25 may have a relatively short portion removed therefrom, as indicated by the dotted lines in the lower left-hand portion of FIG. 4, so that when the two components 25, 26 are assembled, the outer surface of flange 26c may be flush with the free end edge of flange 25c.

Thereafter, the two components 25, 26 are placed in proper relation to each other, as represented by the relative positions of the groove 10a and the tongue 10b of corner joint member 10 (FIGS. 1, 2 and 3). A suitable adhesive is applied to the edge 35 of the still intact severed wing portion 26d of second component 26 and/ or to the severed edge 36 of the first component from which the flange 25b has been removed. Additionally, a suitable adhesive is applied to the free end edge of flange 26c of second component 26' and/or to a portion of the inner surface of flange 250' of first component 25' adjacent the free end thereof. Thereupon, the free edge 35 of that portion of the second component 26' from which a wing portion 26d has been partially severed is adhesively connected to the free edge 36 of that portion of the first component 25' from which a corresponding flange has been severed. Also, the intact flanges 25c, 260' of the first and second components are adhesively interconnected to, thereby form a corner joint member having 6 the external profile configuration of that corner joint member indicated at 10 in FIGS. 1, 2 and 3.

It is apparent that reinforcing strips corresponding to the strips 33, 34 of corner joint member 10 may be applied to the inner surface of flange 26c of second component 26 and to the outer surface of that wall of groove 25a of first component 25 remote from flange 25c, and adjacent the curved outer end of the latter wall, so as to reinforce the corresponding portions of the corner joint member being made from the first and second components 25, 26'. Such reinforcing strips may be made from the flanges 25b, 26b previously severed from the respective components 25', 26'.

It is thus seen that I have provided an improved comer joint member for interconnecting the respectively tongued and grooved edges of a pair of relatively right-angularly disposed wall panels, wherein the corner joint member is of shell-like construction and includes a pair of relatively right-angularly disposed first and second sides with a pair of third and fourth sides having a groove therein and a tongue thereon, respectively, for mating engagement with the tongued and grooved adjacent side edges of the two panels. It is seen further that I have provided a method of making such a corner joint member in which first and second components of respectively substantially M-shaped and U-shaped cross-sectional configuration are modified by removing one of the flanges from each of the same and then adhesively interconnecting the severed edges of the first and second components, as well as adhesively interconnecting intact flanges of the first and second components, and wherein the M-shaped component defines a tongue-receiving groove then positioned in fixed substantially right-angular relation to a tongue defined by the U shaped component.

In the drawings and specification there has been set forth a preferred embodiment of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.

I claim:

1. An elongate corner joint member for interconnecting in substantially right-angular relationship a pair of building wall panels having a longitudinally extending groove and a longitudinally extending tongue on respective proximal edges thereof; said corner joint member comprising first and second unitary and continuous shell-like elements, each element defining two adjacent sides of said member, one of said elements defining a planar side and a longitudinally extending groove of a depth greater than one half the width of said other element planar side, the corresponding free ends of said elements being secured together in generally diagonally opposed relationship with said planar sides abutting and in substantial right-angular relationship and with said groove extending substantially completely behind said tongue with the bottom of the groove being positioned closely adjacent said one element planar side.

2. A corner joint member according to claim 1, wherein said integral elements of said joint member include respective walls defining a continuous external profile cross-sectional configuration to said joint member, and wherein all of said walls are formed of a relatively thin rigid material.

3. A corner joint member according to claim 2, wherein said walls are formed of laminated paper.

4. A comer joint member according to claim 2, including a reinforcing strip extending parallel with and adhesively secured to the inner surface of that wall defining said one element planar side, said reinforcing strip being about the same thickness as said walls, and that wall defining the bottom of said groove being adhesively secured to the inner surface of said reinforcing strip.

5. A corner joint member according to claim 2, wherein opposed sidewalls of said tongue diverge relative to each 7 other toward said other element and wherein the exterior surfaces of those walls defining opposite sides of said groove are rounded at their juncture with said other ele ment planar side and said tongue.

6. A corner joint member according to claim 5, including a reinforcing strip extending parallel with and adhesively secured to the inner surface of that side wall of said groove adjacent said tongue and being positioned in engagement with the inner surface of the corresponding rounded portion of the joint member at the juncture of those adjacent walls defining said groove and said tongue.

7. A corner joint member according to claim 2, wherein those walls of said corner joint member defining said sec ond side and said tongue constitute a first component, and wherein those walls defining said first side and said groove constitute a second component, wherein said walls of the first and second components defining said first and second sides are adhesively interconnected, and also wherein those walls of said first and second components defining said tongue and said groove are adhesively interconnected at their juncture.

8. A corner joint member for connecting together adjacent side edges of a pair of first and second building wall panels in substantially right-angular relationship and wherein the adjacent side edges of said first and second panels have a longitudinally extending groove therein and a longitudinally extending tongue of lesser thickness than that of said panels projecting outwardly therefrom respectively; said joint member comprising an elongate, thinwalled hollow unitary structure having an external profile defining a tongue and a groove extending in substantially right-angular relation to each other, said tongue having outwardly converging opposing side surfaces substantially throughout its length, and said groove being defined by opposing outwardly diverging side surfaces extending substantially throughout the length of said joint member, said hollow unitary structure comprising first and second integral continuous elements, one of which defines said tongue and the other of which defines said groove, each of said elements also defining a respective relatively narrow planar side and said elements being secured together with said groove extending substantially completely behind said tongue for abutment of said elements adjacent the bottom of said groove and with said planar sides in substantially right-angular relation to each other.

9. A four-sided corner joint member for connecting together adjacent side edges of a pair of first and second Wall panels in substantially right-angular relationship and wherein the adjacent side edge of said first panel has a longitudinally extending groove therein and the adjacent side edge of said second panel has a longitudinally extending tongue of lesser thickness than that of said panels projecting outwardly therefrom; said joint member comprislng (a) an elongate thin-Walled tongue element,

(b) an elongate thin-walled groove element,

(c) a pair of elongate, thin-walled, planar first and second sides interconnected in substantiall rightangular relationship to each other,

(d) said tongue and groove elements extending in substantially right-angular relationship to each other,

(e) said tongue element being of lesser width than each of said first and second sides and being spaced from said first side with one elongate side edge portion of said tongue element integrally connected to said second side, and

(f) said groove element being disposed between said first side and said tongue element and having opposing flanged edge portions remote from said second side integrally connected to said tongue element and said first side respectively at points remote from said second side.

References Cited UNITED STATES PATENTS 752,694 2/ 1904 Lund 52595 2,142,305 1/1939 Davis 52--582 2,495,862 1/1950 Osborn 52-580 2,593,714 4/1952 Robinson 52615 2,856,039 10/1958 Hawkinson 52-580 3,238,690 3/1966 Wilkins 52731 FOREIGN PATENTS 247,112 1963 Australia.

HENRY C. SUTHERLAND, Primary Examiner US. Cl. X.R. 52-282, 618

1 FORM PO-IOSDHO-GS) UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No- 3,529,394 Dated September 22, 1970 Inventor(s) W- B. Wilkins It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 6 line 50 after I "extend ing" insert --tongue, the other of said elements defining a planar side and a longitudinally extending--.

SIGNED MM FALED new 1 7m I J'- W 1. JR-

hi 8 Gomissiom 01' moms 

